Reel based closure system employing a friction based tension mechanism

ABSTRACT

A reel based tensioning device includes a housing, a spool that is rotatably positioned within the housing, and a knob member that is operably coupled with the spool to cause the spool to rotate in a first direction within the housing and thereby wind a tension member about the spool. The reel based tensioning device also includes a load holding mechanism that is coupled with the spool and that is configured the spool to rotate in the first direction within the housing and to prevent rotation of the spool in a second direction to prevent unwinding of the tension member from about the spool. The reel based tensioning device further includes an audible component that is configured to produce an audible noise responsive to operation of the knob member to signal an adjustment of the tension member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Provisional U.S. Patent ApplicationNo. 62/465,342 filed Mar. 1, 2017, entitled “Reel Based Closure SystemEmploying Friction Based Tension Mechanism” and Provisional U.S. PatentApplication No. 62/464,050 filed Feb. 27, 2017, entitled “Reel BasedSystem With Magnetic Coupling Mechanism.” The entire disclosure of bothof the aforementioned Provisional U.S. Patent Applications are herebyincorporated by reference, for all purposes, as if fully set forthherein.

BACKGROUND OF THE INVENTION

The present disclosure is related to reel based closure devices forvarious articles, such as braces, medical devices, shoes, clothing,apparel, and the like. Such articles typically include some closuresystem, which allows the article to be placed about a body part andclosed or tightened about the body part. The closure systems aretypically used to maintain or secure the article about the body part.For example, shoes are typically placed over an individual's foot andthe shoelace is tensioned and tied to close and secure the shoe aboutthe foot. Conventional closure systems have been modified in an effortto increase the fit and/or comfort of the article about the body part.For example, shoe lacing configurations and/or patterns have beenmodified in an attempt to increase the fit and/or comfort of wearingshoes. Conventional closure systems have also been modified in an effortto decrease the time in which an article may be closed and secured aboutthe body part. These modifications have resulted in the use of variouspull cords, straps, and tensioning devices that enable the article to bequickly closed and secured to the foot.

BRIEF DESCRIPTION OF THE INVENTION

The embodiments described herein provide reel based tensioning devices,and components therefor, that may be used to tension a lace or tensionmember and thereby tighten an article or other item. According to oneaspect, an insert molded component for a reel based tensioning deviceincludes a base member of a reel based tensioning device and a fabricmaterial. The base member is typically made of a polymer material andincludes a top end and a bottom end with a bottom surface. The basemember has an interior cavity within which one or more components of thereel based tensioning device are positionable. The fabric material issubstantially flush with the bottom surface of the base member andextends laterally from at least a portion of an outer periphery of thebottom end of the base member. The base member is insert molded onto thefabric material by injecting the polymer material through the fabricmaterial so that when the insert molded component is formed, the fabricmaterial is disposed within at least a portion of the base member withthe polymer material of the least a portion of the base member beingdisposed on opposite sides of the fabric material.

According to another aspect, a component of a reel based tensioningsystem includes a first component that is made of a polymer material andthat includes a top end, a bottom end, and an interior cavity withinwhich a second component of the reel based tensioning system ispositionable. The component also includes a fabric material that ispositioned near the bottom end of the first component and that extendslaterally from at least a portion of an outer periphery of the firstcomponent. The fabric material is integrally coupled with the firstcomponent by injecting the polymer material of the first componentthrough the fabric material so that the polymer material of at least aportion of the first component is saturated or impregnated through thefabric material and so that the polymer material of the at least aportion of the first component extends axially bellow a bottom surfaceof the fabric material and axially above a top surface of the fabricmaterial.

According to another aspect, a method of forming a component of a reelbased tensioning system includes providing a fabric material,positioning the fabric material within a die or mold, and injecting apolymer material through the fabric material so that the polymermaterial fills a void or space within the die or mold that defines ashape of a first component of the reel based tensioning system. Themethod also includes cooling the polymer material so that the polymermaterial hardens and forms the first component of the reel basedtensioning system. The polymer material of at least a portion of thefirst component is saturated or impregnated through the fabric materialso that the polymer material of the at least a portion of the firstcomponent extends axially bellow a bottom surface of the fabric materialand axially above a top surface of the fabric material.

According to another aspect, a reel based tensioning device includes ahousing having an interior region and a spool positioned within theinterior region of the housing and rotatable relative thereto. The reelbased tensioning device also includes a knob member that is operablycoupled with the spool to cause the spool to rotate in a first directionwithin the interior region of the housing to wind a tension member aboutthe spool and thereby tension the tension member. The reel basedtensioning device further includes a load holding mechanism that iscoupled with the spool and that is configured to allow rotation of thespool in the first direction within the interior region of the housingand to prevent rotation of the spool in a second direction within theinterior region of the housing to prevent unwinding of the tensionmember from about the spool. The reel based tensioning deviceadditionally includes an audible component that is separate from theload holding mechanism and that is configured to produce an audiblenoise in response to operation of the knob member to audibly signal anadjustment in tension of the tension member.

According to another aspect, a reel based tensioning device includes ahousing, a spool rotatably positioned within the housing, a knob memberthat is operably coupled with the spool to cause the spool to rotate ina first direction within the housing to wind a tension member about thespool, a load holding mechanism that is coupled with the spool andconfigured to allow rotation of the spool in the first direction withinthe housing and to prevent rotation of the spool in a second directionwithin the housing to prevent unwinding of the tension member from aboutthe spool, and an audible component that is configured to produce anaudible noise responsive to operation of the knob member to signal anadjustment of the tension member.

According to another aspect, a method of configuring a reel basedtensioning device includes providing the reel based tensioning device,in which the reel based tensioning device includes a housing, a spoolrotatably positioned within the housing, a knob member that is operablycoupled with the spool to cause the spool to rotate in a first directionwithin the housing to wind a tension member about the spool, and a loadholding mechanism that is coupled with the spool and that is configuredto allow rotation of the spool in the first direction within the housingand to prevent rotation of the spool in a second direction within thehousing to prevent unwinding of the tension member from about the spool.The method also includes coupling an audible component with the reelbased tensioning device, in which the audible component is configured toproduce an audible noise responsive to operation of the knob member tosignal an adjustment of the tension member.

According to another aspect, a reel based tensioning device fortightening an article includes a housing having an interior region, aspool positioned within the interior region of the housing and rotatablerelative thereto, a knob member that is operably coupled with the spoolto cause the spool to rotate within the interior region of the housing,and a load holding mechanism that is coupled with the spool. The loadholding mechanism includes a spring that frictionally engages with acylindrical member to prevent rotation of the spool within the interiorregion of the housing responsive to forces imparted on the spool from asource other than the knob member, such as tension in the tension memberthat imparts a rotational force on the spool. The knob is operationallycoupled with the load holding mechanism so that a rotation of the knobin a first direction reduces the frictional engagement of the spring andcylindrical member in order to allow rotation of the spool in the firstdirection within the interior region of the housing and thereby wind atension member about the spool. The knob is also operationally coupledwith the load holding mechanism so that a rotation of the knob in asecond direction also reduces the frictional engagement of the springand cylindrical member in order to allow rotation of the spool in thesecond direction within the interior region of the housing and therebyunwind the tension member from about the spool.

According to another aspect, a reel based tensioning device includes ahousing, a spool that is rotatably positioned within the housing, a knobmember that is operably coupled with the spool to cause the spool torotate within the housing, and a load holding mechanism that includes aspring that frictionally engages with a cylindrical member to preventunwanted rotation of the spool within the housing. The knob member isoperationally coupled with the load holding mechanism so that a firstoperation of the knob member reduces the frictional engagement of thespring and cylindrical member to allow rotation of the spool within thehousing to wind a tension member about the spool and so that a secondoperation of the knob member also reduces the frictional engagement ofthe spring and cylindrical member to allow rotation of the spool withinthe housing to unwind the tension member from about the spool.

According to another aspect, a method for assembly an article with areel based tensioning device includes providing a reel based tensioningdevice, in which the reel based tensioning device includes a housing, aspool that is rotatably positioned within the housing, a knob memberthat is operably coupled with the spool to cause the spool to rotatewithin the housing, and a load holding mechanism that includes a springthat frictionally engages with a cylindrical member to prevent unwantedrotation of the spool within the housing. The knob member isoperationally coupled with the load holding mechanism so that a firstoperation of the knob member reduces the frictional engagement of thespring and cylindrical member to allow rotation of the spool within thehousing to wind a tension member about the spool and a second operationof the knob member also reduces the frictional engagement of the springand cylindrical member to allow rotation of the spool within the housingto unwind the tension member from about the spool. The method alsoincludes coupling the reel based tensioning device member with thearticle.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in conjunction with the appendedfigures:

FIG. 1 illustrates a perspective view of an assembled reel systemshowing a knob attached to a housing, which is typically coupled with abase member.

FIGS. 2-3 illustrate exploded perspective views of the reel system ofFIG. 1 showing various internal components of the reel system.

FIG. 4 illustrates a pawl member or beam of an audible component ormechanism.

FIG. 5 illustrates a perspective view of a knob member of the reelsystem of FIG. 1.

FIGS. 6-7 illustrate an upper hub and a lower hub that may be employedin the reel system of FIG. 1.

FIG. 8 illustrate a coil spring that may be employed with the upper huband the lower hub of FIGS. 6-7.

FIG. 9 illustrates an embodiment of a spool that may be employed in thereel system of FIG. 1.

FIG. 10 illustrates an exploded perspective view of a release hub andthe upper hub, the lower hub, and the coil spring of FIGS. 6-8.

FIG. 11 illustrates an assembled view of the release hub, the upper hub,the lower hub, and the coil spring of FIG. 10.

FIG. 12 illustrates a knob member and housing of the reel system of FIG.1 in which the knob member is rotated in a tightening direction inrelation to the housing.

FIG. 13 illustrates the knob member and housing in which the knob memberis rotated in a loosening direction in relation to the housing.

FIG. 14 illustrates a perspective view of an audible component ormechanism of the reel system of FIG. 1 that may be employed to producean audible noise.

FIGS. 15, 17-19, & 23-25 illustrate various views of a base member, awoven material or fabric, and a coupling of the base member and wovenmaterial or fabric.

FIG. 16 illustrates a housing of the reel system of FIG. 1 and variousfeatures of the housing.

FIG. 20 illustrates a stop cord or mechanism that may be attached to aspool and housing of the reel system of FIG. 1.

FIGS. 21-22 illustrate an alternative embodiment of a coil spring andrelease hub assembly that may be employed in the reel system of FIG. 1.

FIGS. 26-30 illustrate an alternative embodiment of a friction basedload holding mechanism that may be employed in the reel system of FIG. 1and that includes a single hub and coil spring.

In the appended figures, similar components and/or features may have thesame numerical reference label. Further, various components of the sametype may be distinguished by following the reference label by a letterthat distinguishes among the similar components and/or features. If onlythe first numerical reference label is used in the specification, thedescription is applicable to any one of the similar components and/orfeatures having the same first numerical reference label irrespective ofthe letter suffix.

DETAILED DESCRIPTION OF THE INVENTION

The ensuing description provides exemplary embodiments only, and is notintended to limit the scope, applicability or configuration of thedisclosure. Rather, the ensuing description of the exemplary embodimentswill provide those skilled in the art with an enabling description forimplementing one or more exemplary embodiments. It being understood thatvarious changes may be made in the function and arrangement of elementswithout departing from the spirit and scope of the invention as setforth in the appended claims.

The embodiments herein describe reel based closure or tensioning devicesthat may be used to tension a lace or tension member and thereby tightenan article or other item. The reel based tensioning devices are alsoreferred to herein as reel systems or simply closure devices. Thearticle may be a variety of items including a pack (i.e., back pack,book bag, etc.), an article of clothing (i.e., hats, gloves, belt,etc.), sports apparel (boots, snowboard boots, ski boots, etc.), medicalbraces (i.e., back braces, knee braces, wrist brace, ankle brace, etc.),and/or various other items or apparel. A specific embodiment in whichthe closure system may be employed involves footwear, such as shoes,boots, sandals, etc.

The reel systems herein employ friction based tension adjustmentmechanisms, which are used to tension a lace, cord, or tension member(hereinafter tension member) and to maintain the tension of the tensionmember. The friction based tension adjustment mechanisms describedherein employ a load holding mechanism having a spring (e.g., a coilspring) that frictionally engages with a cylindrical member, such as aboss or hub, in order to provide a load holding function that maintainsthe tension in the tension member. Specifically, the frictionalengagement of the spring and the cylindrical member is employed toprevent unwanted rotation of a spool within the housing. Since the reelsystems are used to maintain tension in the tension member, unwantedrotation of the spool means any rotation of the spool that is notinitiated by a user and that would result in loosening or un-tensioningof the tension member. Stated differently, the system is designed sothat the spool will rotate only in response to an action by the user toloosen or un-tension the lace, which commonly involves a rotation of aknob component of the reel system in a loosening direction, but couldalso involve other actions, such as operating a lever, pressing abutton, pulling axially upward on the knob, and the like. Absent thisaction by the user, the spring and the cylindrical member are designedto frictionally engage and prevent rotation of the spool within thehousing.

The reel system typically includes a knob that is designed to be graspedand rotated by a user. The knob member is operationally coupled with theload holding mechanism so that a first operation of the knob member(e.g., rotation of the knob in a tightening direction) reduces thefrictional engagement of the spring and cylindrical member to allowrotation of the spool within the housing to wind the tension memberabout the spool. The knob member is also operationally coupled with theload holding mechanism so that a second operation of the knob member(e.g., rotation of the knob in a loosening direction) reduces thefrictional engagement of the spring and cylindrical member to allowrotation of the spool within the housing to unwind the tension memberfrom about the spool.

In an exemplary embodiment, the coil spring is positioned or wound aboutan exterior of a hub member or central cylindrical boss. The coil springis configured to constrict about the hub member or central cylindricalboss in order to provide the load holding function. In one embodiment,the hub member or central cylindrical boss may include an upper hubmember that is fixedly secured to the spool and a lower hub member thatis fixedly secured to the housing. The upper hub member may have adiameter that is slightly larger than a diameter of the lower hubmember. In such embodiments, a distal end of the upper hub member thatinterfaces with the lower hub member may be tapered. In anotherembodiment, the hub member or central cylindrical boss may be an innerhub member and the reel system may also include an outer hub member thatis disposed over the inner hub member and that is operationally coupledwith the knob member and the spring so that a rotation of the knobmember in a loosening direction reduces the frictional engagement of thespring and the inner hub member. In such embodiments, the outer hubmember may be coupled with the knob member such that rotation of theknob member in the loosening direction effects a rotation of the outerhub in the loosening direction. The spring may include a tang that iscoupled with the outer hub member so that rotation of the outer hubmember in the loosening direction effects a widening of a diameter ofthe spring thereby reducing the frictional engagement of the spring andthe inner hub member. In yet another embodiment, the coil spring may bepositioned within a cylindrical channel or recess of a boss or hub. Insuch embodiments, the coil spring is biased to flex radially outward andinto frictional engagement with an interior wall of the cylindricalchannel or recess in order to provide the load holding function.

The friction based tension adjustment mechanism eliminates the need forpawls or flexible arms that are commonly used in conventional systems toprovide the load holding functions. In such conventional systems, a pawlor arm commonly engages with teeth in order to provide the load holdingfunction. The pawl/arm and teeth are often sloped or configured toenable a one-way motion of the pawl/arm and thereby the reel baseddevice, such as rotation of a knob in a tightening direction. Thepawl/arm and teeth lockingly engage when the knob is rotated in anopposite direction in order to prevent rotation of one or morecomponents of the system that would loosen the tension in the tensionmember. The embodiments herein may be entirely free of a pawl or armthat functions to provide load holding capabilities. In otherembodiments, the reel system may include a combination of a frictionbased mechanism and a pawl or arm in order to provide the load holdingfunctions.

The load holding mechanism described herein (i.e., the spring and hubmember) may not produce an audible noise that is detectable by a humanear. As such, the reel system may include an audible component that isconfigured to produce an audible noise responsive to operation of theknob member to signal an adjustment of the tension member. The audiblecomponent may be configured to produce an audible noise responsive totensioning of the tension member and to produce an audible noiseresponsive to loosening of the tension member. The audible noise that isproduced responsive to tensioning of the tension member may be differentthan the audible noise responsive to loosening of the tension member.The audible component may be coupled with a top surface of the spool.

While the systems herein are commonly devoid of a load holding pawl orarm, in the exemplary embodiment, a separate pawl system, member, orbeam may be used to produce the audible noise or sound when the systemis operated. For example, the pawl system, member, or beam may be usedprimarily to produce a click sound when the knob is rotated, whichaudibly indicates to a user that the system is being used to tension orloosen the tension member. The pawl system, member, or beam may provideaudible feedback that users of the system may expect and/or desire. Thepawl system, member, or beam may be incapable of preventing rotation ofthe spool within the housing when an appreciable rotational force isimposed on the spool via the tension member or knob member. For example,when the user rotates the knob member in a loosening direction, the pawlsystem, member, or beam may not appreciably impede the rotation of theknob member.

Additional features and aspects of the reel based closure devices willbe evident with references to the description of the several drawingswhich is provided herein below.

FIG. 1 illustrates an assembled perspective view of the reel system 100.The assembled reel system 100 shows a knob 170 attached to a housing102, which is typically coupled with a base member 220. The housing 102is coupled with the base member 220 in a manner that allows the housing102 to be detached or removed from the base member 220. Coupling of thehousing 102 and base member is achieved via engagement of matingfeatures that are positioned on both components. FIG. 1 illustrates alip or flange member 106 that is positionable within a front tab 222 ofthe base member 220 to couple the front portion of the housing 102 tothe base member 220. FIG. 16 illustrates tabs 110 that are positioned onan opposite side of the housing 102. The tabs 110 are designed to fitwithin corresponding slots on an interior surface of a wall 224 thatpartially surrounds the periphery of the base member 220. FIG. 16 alsoillustrates lace ports 104 of the housing 102. The lace ports include anopening 105 within which the tension member is inserted to allow thetension member to access the interior of the housing 102. As illustratedin FIG. 17, the base member 220 includes open portions or areas onopposing sides of the front tab 222 that are shaped and sized toaccommodate the lace ports 104, which provides a visual appearance ofthe base member 220 and housing 102 being a unitary component.

The housing 102 is shaped so that it corresponds with an outer surfaceof the base member 220 and with the outer surface of the knob 170. Forexample, when the housing 102 is attached to the base member 220, theouter surfaces of these components align so that they appear as acontinuous or matching surface. The matching outer surfaces of thehousing 102 and the base member 220 helps to conceal or hide the edgesof both components. In this manner, the user does not readily perceivethe separate edges of the components, but rather visually perceives theseparate components as an integral unit. The outer surface of thehousing 102 similarly aligns with the knob 170 so that the outersurfaces appear to flow together. The alignment of the knob 170 andouter surface of the housing 102 also eliminates or minimizes ridges oredges that could catch on surrounding objects and open the system orseparate the knob 170 from the housing 102. The shape of the housing102, knob 170, and base member 220 provides a visually appealing lookthat users may desire.

The knob 170 is coupled with the housing 102 via a snap engagement orfit. Specifically, an inner surface of the knob 170 include radiallyinwardly protruding tabs 176 that are configured to snap over a radiallyoutwardly protruding rib 114 of the housing 102. The knob 170 may flexradially outward slightly as the two components are snap fit together.The snap fit engagement or coupling allows the components to be attachedtogether without the use of a screw, bolt, or other similar mechanicalfastener. An exemplary embodiment of a snap fit coupling of a knob andhousing is further described in U.S. patent application Ser. No.14/297,047, filed Jun. 5, 2014, and entitled “Integrated Closure DeviceComponents and Methods,” the entire disclosure of which is incorporatedby reference herein.

FIGS. 1 and 5 illustrate the knob 170 having a textured or patternedouter rim 173, which in some instances may have a knurled configuration.The textured or patterned outer rim may enhance the grip surface of therim 173 of the knob 170 and/or may be employed for aesthetic appeal. Insome instances, the knob 170 may be made of a metal material, such asaluminum or stainless steel. In such instances, the textured orpatterned outer rim 173 may significantly enhance the grip properties ofthe knob 170. In other instances, the knob 170 may be made of plasticmaterials, such as polypropylene, polyethylene, nylon, and the like.

FIGS. 2 and 3 illustrate exploded perspective view of the reel system100. The internal components of the reel system 100 are visible in FIGS.2 and 3. The term “internal components” implies the components of thesystem that are disposed within an interior region 116 of the housing102 and axially below the knob 170 so that in the assembled view, theinternal components are not visible. The internal components include aspool 140, a friction based load holding mechanism 120, an audiblefeedback assembly 160, and a stop cord or mechanism 230 (see FIG. 20).Each of these components is described in greater detail in relation toFIGS. 2-20, which provide detailed perspective views of the variouscomponents.

The spool 140 is rotatably positioned within the interior region 116 ofthe housing 102. A detailed perspective view of the spool 140 isillustrated in FIG. 9. The spool 140 is configured to rotate around acylindrical coupling post 190 that attaches to a central boss 115 of thehousing 102. The cylindrical coupling post 190 is inserted through acentral aperture 148 of the spool 140 and attaches to the central boss115 of the housing 102 by inserting or press fitting a distal end of thecylindrical coupling post 190 within an aperture of the housing'scentral boss 115 (see FIG. 16). FIG. 16 illustrates the cylindricalcoupling post 190 press fit or inserted within the aperture of thecentral boss 115. The cylindrical coupling post 190 may be secured tothe central boss 115 via an interference fit, adhesive bonding, welding(RF, sonic, etc.), and the like. The spool's aperture 148 issufficiently large so as to minimize frictional forces between the spool140 and cylindrical coupling post 190 and thereby enable the spool 140to freely rotate about the cylindrical coupling post 190 within theinterior region 116 of the housing 102.

The spool's aperture 148 is centrally positioned within a recessedportion of the upper surface of the spool 140. The recessed portion ofthe upper surface of the spool 140 is shaped and sized to accommodate acap of the cylindrical coupling post 190. When the cap of thecylindrical coupling post 190 is positioned within the recessed portionof the spool 140, an upper surface of the cap may align with the uppersurface of the spool 140.

The spool 140 includes a lace take up region, such as an annular channel144, around which the tension member (not shown) is wound and unwound inorder to tension and loosen the tension member. The spool 140 isoperationally coupled with the knob 170 so that rotation of the knob 170in a tightening direction (e.g., clockwise) and a loosening direction(e.g., counter-clockwise) effects a corresponding rotation of the spool140 within the interior region 116 of the housing 102. The knob 170includes one or more drive components or tabs 174 that are positionedwithin a window 150 of the spool 140. In the illustrated embodiment, thereel system 100 includes three drive tabs 174 and three windows 150,although more or fewer of these components may be employed as desired.

The drive tabs 174 are sized smaller than the windows 150 so that thedrive tabs 174 are rotatable by some amount within the windows 150between opposing inner sides or edges 152 of the window 150. Therelative rotation of the drive tabs 174 within the windows 150 allowsthe knob 170 to be rotated about the housing 102 by some amount withouteffecting a tightening or loosening of the tension member. The smallersized drive tabs 174 facilitate in releasing the friction based loadholding mechanism 120 as described herein. FIGS. 12 and 13 illustratethe drive tabs 174 rotating between the opposing sides 152 of thewindows 150 and being used in a manner that enables tensioning andloosening of the tension member by causing the spool 140 to rotatewithin the interior region 116 of the housing 102.

The bottom or rear surface of the spool 140 includes a large cylindricalopening or channel 142 within which the friction based load holdingmechanism 120 is positioned. As illustrated in FIG. 10, the frictionbased load holding mechanism 120 includes an upper hub 126, a lower hub122, a coil spring 134, and a release sleeve 134, all or most of whichare coaxially aligned and positioned within the opening or channel 142of the spool 140. The upper hub 126, lower hub 122, and release sleeve130 all include axially extending teeth. Specifically, the upper hub 126includes axially extending teeth 128, the lower hub includes axiallyextending teeth 124, and the release sleeve 130 includes axiallyextending teeth 132. The axially extending teeth, 128 and 124, of theupper hub 126 and lower hub 122 are oriented so that the teeth extend inopposing directions. The release sleeve 130 is oriented so that itsaxially extending teeth 132 extend in the same direction as the axiallyextending teeth 128 of the upper hub 126.

The upper hub 126 is positioned within the cylindrical opening 142 ofthe spool 140 so that its axially extending teeth 128 are insertedwithin corresponding apertures 158 of the spool 140, which locks orfixedly secures the upper hub 126 to the spool 140. Fixedly securing theupper hub 126 to the spool 140 means that the upper hub 126 does nottranslate or rotate relative to the spool 140. Rather, rotational motionor movement of the spool 140 causes a corresponding rotational motion ormovement of the upper hub 126 since the two components are fixedlysecured together. The lower hub 122 is similarly positioned within theinterior region 116 of the housing 102 so that its axial extending teeth124 are inserted within corresponding apertures 107 of the housing 102,which locks or fixedly secures the lower hub 122 to the housing 102.When coupled with the base member 220, the housing 102 is fixed inposition relative to the base member 220. Since the lower hub 122 islocked or fixedly secured to the housing 102, the lower hub 122 is fixedin position relative to the base member and housing and thus, the lowerhub 122 is not rotatable or translatable relative to the reel system100.

The coil spring 134 is positioned over the upper hub 126 and the lowerhub 122. The release sleeve 130 is in turn positioned over the coilspring 134 so that the coil spring 134, the upper hub 126, and the lowerhub 112 are positioned within the cylindrically interior region of therelease sleeve 130. The coil spring 134 surrounds the upper hub 126 andthe lower hub 122 in a manner that allows the coil spring 134 toconstrict about the outer surfaces of these hubs, 126 and 122.Specifically, the coil spring 134 has an inner diameter that isapproximately the same as, or slightly smaller, than an outer diameterof the upper hub 126 and the lower hub 122. The coil spring 134frictionally engages with the upper hub 126 and the lower hub 122 byconstricting about the outer surface of said hubs, 122 and 126. Thefrictional engagement of the coil spring 134 and the upper and lowerhubs, 126 and 122, provides the load holding property or function of thefriction based load holding mechanism 120. Specifically, theconstriction of the coil spring 134 about the upper hub 126 and thelower hub 122 locks or secures the upper hub 126 and lower hub 122 inrelation to one another by preventing the upper hub 126 from rotatingabout or relative to the lower hub 122. Locking the upper hub 126 andthe lower hub 122 together in this manner locks the spool 140 inposition relative to the housing 102 since the spool 140 is fixedlysecured to the upper hub 126. This prevents the spool 140 from spinningor rotating within the interior region 116 of the housing 102, whichmaintains a tension that exists in the tension member.

The coil spring 134 is designed so that when the knob 170 is rotated inthe tightening direction (e.g., Arrow A in FIG. 12), the coil spring 134is able to rotate about the lower hub 122, which is fixed in positonabout the housing 102. The coil spring 134 typically stays fixed inposition about the upper hub 126 and rotates in the tightening directionalong with the upper hub 126, the release sleeve 130, the spool 140, andthe knob 170. Maintaining a proper alignment of the upper hub 126, thecoil spring 134, and the release sleeve 130 is important in delivering aconsistent and repeatable tensioning and loosening feel and performanceof the reel system 100 as described herein. Rotation of these componentsin the tightening direction causes the tension member to be wound aboutthe annular channel 144 of the spool 140, which increases the tension inthe tension member. When rotation of the knob 170 in the tighteningdirection ceases, the coil spring 134 constricts about the upper andlower hubs, 126 and 122, thereby locking or securing these componentstogether and preventing rotation of the spool 140 and other componentsin the loosening direction (e.g., Arrow B of FIG. 13). The tension inthe tension member typically biases the spool 140 toward rotation in theloosening direction, which increases the frictional engagement of thecoil spring 134 and upper and lower hubs, 126 and 122. The increasedfrictional engagement of these components further locks, or more fixedlysecures, the upper and lower hubs, 126 and 122, together.

The release sleeve 130 is used to adjust the frictional engagement ofthe coil spring 134 about the upper and lower hubs, 126 and 122, inorder to allow the hubs, 126 and 122, to rotate relative to one anotherand thereby allow the spool 140 to spin within the interior region 116of the housing 102. Specifically, the release sleeve 130 isoperationally coupled with the knob 170 so that rotation of the knob 170in the loosening direction causes a lower portion of the release sleeve130 to rotate in the loosening direction. As illustrated in FIG. 13, asthe knob 170 is rotated in the loosening direction, the drive tabs 174of the knob 170 engage the axially extending teeth 132 of the releasesleeve 130, which causes the release sleeve 130 to rotate in theloosening direction.

As illustrated in FIG. 11, an opposite end of the release sleeve 130 isattached to a radially extending tang 136 of the coil spring 134 so thatrotation of the release sleeve 130 in the loosening direction presses onthe tang 136 which causes the coil spring 134 to open slightly.Specifically, as the release sleeve 130 rotates in the looseningdirection, the tang 136 is pressed and rotated in the looseningdirection, which causes the lower coil portions of the coil spring 134to radially open or widen, thereby reducing the frictional engagement ofthe lower coil portions and the lower hub 122. The reduced frictionalengagement of the coil spring 134 and lower hub 122 allows the lowercoil portions of the coil spring 134 to rotate about the lower hub 122in the loosening direction.

The upper portions of the coil spring 134 remain fixed in position aboutthe upper hub 126 so that the upper portions of the coil spring 134 donot rotate about, or relative to, the upper hub 126. Since the lowerportions of the coil spring 134 are rotatable about the lower hub 122via the release sleeve 130, the upper hub 126 and coil spring 134 may berotated in the loosening direction. In this manner the release sleeve130 enables the upper hub 126 to be unlocked or uncoupled from the lowerhub 122, which allows the upper hub 126 and coil spring 134 to berotated in the loosening direction in response to rotation of the knob170 in the loosening direction. Since the upper hub 126 is attached tothe spool 140, uncoupling the upper and lower hubs, 126 and 122, allowsthe spool 140 to be rotated in the loosening direction in response torotation of the knob 170 in the loosening direction, which unwinds thetension member from the annular channel 144 and thereby reduces tensionin the tension member. When rotation of the knob 170 in the looseningdirection ceases, the lower portion of the coil spring 134 constrictsabout the lower hub 122, which locks or couples the upper and lowerhubs, 126 and 122, and thereby prevents further rotation of the upperhub 126, the coil spring 134, and the spool 140 in the looseningdirection.

The release sleeve 130 is sized radially larger than the coil spring 134to ensure that the release sleeve 130 does not frictionally engage with,or minimally engages with, the coil spring 134, which engagement mayimpede rotation of the release sleeve 130 relative to the coil spring134.

As briefly described above, it is desirable to maintain an orientationof the upper hub 126, the coil spring 134, the release sleeve 130, andthe spool 140. A proper orientation of these components is important toensure that rotation of the knob 170 in the loosening direction causesthe release sleeve 130 to engage the tang 136 in a consistent andrepeatable manner, which ensures that the tightening and loosening ofthe tension member remains relatively constant. As illustrated in FIGS.12 and 13, the axially extending teeth 132 and the drive tabs 174 arepositioned within the windows 150 of the spool 140. In order to achievea repeatable and consistent engagement of the tang 136, it is importantto maintain the orientation or relative positions of the axiallyextending teeth 132 and the drive tabs 174 within the window 150.Otherwise, the drive tabs 174 will not properly engage the axiallyextending teeth 132 of the release sleeve 130 to cause the releasesleeve 130 to rotate and open the lower coil portions of the coil spring134 as described above.

To maintain the orientation of these components, it is important thatthe upper coil portions of the coil spring 134 remain fixed about theupper hub 126. Specifically, it is important that the coil spring 134does not rotate relative to the upper hub 126, but rather only rotatesrelative to or about the lower hub 122. To ensure that the coil spring134 rotates about the lower hub 122 only and remains fixed or secured tothe upper hub 126, one or more of the following upper and lower hubconfigurations may be employed: the upper hub 126 may have a slightlylarger diameter than the lower hub 122, the upper hub 126 may be made ofa material having a greater coefficient of friction than the lower hub122, the lower hub 122 may have a surface finish that substantiallyreduces the frictional coefficient in comparison with the upper hub 126.Any combination of these options may be employed to ensure that the coilspring 134 only rotates about the lower hub 122.

For example, as illustrated in FIGS. 6 and 7, the upper hub 126 may havea diameter D₁ that is larger than a diameter D₂ of the lower hub 122.The larger diameter D₁ of the upper hub 126 ensures that the coil spring134 constricts about and is more frictionally engaged with the upper hub126 than the lower hub 122. In some embodiments, the difference indiameter between the upper and lower hubs, 126 and 122, is approximately2 mm. The 2 mm diameter difference is sufficient to ensure that the coilspring 134 remains frictionally engaged with, and secured to, the upperhub 126 without significantly affecting the load holding power of thesystem, which may occur when the difference in diameter between theupper hub 126 and the lower hub 122 is too substantial. If thedifference in diameter between the upper hub 126 and the lower hub 122is too great, the coil spring 134 may not be able to sufficientlyconstrict about the lower hub 122 and thus, the coil spring 134 may notbe able to lock or secure the upper and lower hubs, 126 and 122,together.

To help ensure that the coil spring 134 is able to properly constrictabout the different sized hubs, the upper hub 126 includes a tapereddistal end 127, which provides a transition between the larger diameterupper hub 126 and the smaller diameter lower hub 122. The tapered distalend 127 ensures that a rough step or abrupt edge is not formed at aninterface between the two hubs, which may negatively affect the holdingpower of the reel system 100 by limiting the ability of the coil spring134 to grip and constrict about the outer surface of the lower hub 122.The tapered distal end 127 allows the coil spring 134 to constrict andgrip about the outer surface of the lower hub 122 despite the differencein size of the upper and lower hub. In addition, the upper hub 126 maybe made of a material having a greater coefficient of friction than thelower hub 122. For example, the upper hub 126 may be made of aluminumwhile the lower hub 122 is made of brass or bronze. The surface finishof the lower hub 122 may further, or alternatively, reduce thefrictional coefficient of the lower hub 122. For example, the lower hub122 may have a polished surface finish in comparison with the upper hub126, which may substantially reduce the frictional coefficient of thelower hub 122.

To maintain the orientation of the components, it is also important toensure a proper alignment of the release sleeve 130 and the coilspring's tang 136. The alignment of the release sleeve 130 and tang 136is important to ensure that rotation of the release sleeve 130 in theloosening direction immediately engages the tang 136. In some instances,the distal end of the release sleeve 130 may include a notch or slotwithin which the tang 136 is positioned. In the instant embodiment,however, the tang 136 is inserted directly into the distal end of therelease sleeve 130 as shown in FIG. 11. One method of directly insertingthe tang 136 into the distal end of the release sleeve 130 is via heatstaking the tang 136 into the release sleeve 130. Directly inserting thetang 136 into the release sleeve 130 eliminates or substantiallyminimizes any issues associated with manufacturing tolerances, which mayvary the relative position of the tang 136 about the release sleeve 130and significantly affect how the coil spring 134 opens in response tocounter-rotation of the knob 170 and release sleeve 130.

Since the coil spring 134 is wrapped around the upper and lower hubsmultiple times, any variance in the diameter of either hub, 126 and 122,can significantly affect the position of the tang 136 in relation to therelease sleeve 130. For example, a change in diameter of either hubresults in a change in the position of the tang 136 relative to therelease sleeve 130 that can be modeled by the equation V=NπΔD, where Vis the variance in the position of the tang 136 about release sleeve130, N is the number of wrappings of the coil spring 134, and AD is thechange in the diameter of either hub. It has been observed that smallvariations in the diameter of either or both hubs, 126 and 122, canchange the position of the tang 136 by up to 1 mm, which can greatlyaffect how much the coil spring 134 opens or widens in response tocounter-rotation of the release sleeve 130. Directly inserting the tang136 into the distal end of the release sleeve 130, via heat staking orsome other method, negates the affects that any variance in thecomponents of the reel system 100 may have. Rather, directly insertingthe tang 136 into the release sleeve 130 ensures a proper and precisealignment regardless of any variance experienced in the system.Eliminating or reducing the variance in the positioning of the tang 136about the release sleeve 130 typically results in a more consistent andrepeatable system performance and feel in tensioning and loosening thetension member.

In some embodiments, the coil spring 134 may be wrapped about the upperand lower hubs, 126 and 122, about 7 times.

FIGS. 12 and 13 illustrate the interaction of the knob 170, the spool140, and the release sleeve 130 in adjusting the tension of a tensionmember. FIG. 12 illustrates these components being used to increase thetension of the tension member by winding the tension member around thespool's annular channel 144 while FIG. 13 illustrates these componentsbeing used to reduce the tension of the tension member by unwinding thetension member from around the spool's annular channel 144. In thefigures, the upper surface of the knob 170 is removed so that the drivetabs 174 of the knob 170, the axially extending teeth 132 of the releasesleeve 130, the upper surface of the spool 140, and the spool's windows150 are visible. As shown in FIG. 12, rotation of the knob 170 in thetightening direction, which is represented by Arrow A, causes the drivetab 174 to contact a first tooth 132 a of the release sleeve 130 and afront edge 152 a of the spool's window 150 (the first tooth 132 a isshown exposed in FIG. 13). Contact between the drive tab 174 and thefirst tooth 132 a causes the release sleeve 130 to rotate relative tothe spool 130, which causes the first tooth 132 a to rotate out of thewindow 150 and under the upper surface of the spool 140. Rotation of therelease sleeve 130 in this manner causes a second tooth 132 b to rotateinto the window 150 on an opposite side of the drive tab 174 asillustrated in FIG. 12.

Contact between the drive tab 174 and the front edge 152 a of thespool's window 150 transfers rotational forces between the knob 170 andthe spool 140. Thus, rotation of the knob 170 in the tighteningdirection causes the spool to likewise rotate in the tighteningdirection, which causes the tension member to be wound about the spool'sannular channel 144. As illustrated, the instant embodiment includesthree drive tabs 174, windows 150, and first teeth 132 a, although moreor fewer of these components may be employed. In some embodiments, therelease sleeve 130 does not include the first tooth 132 a and insteadrotational forces are transferred to the release sleeve 130 via the coilspring 134 and tang 136.

As shown in FIG. 13, rotation of the knob 170 in a counter direction(i.e., the loosening direction), which is illustrated by Arrow B, causesthe drive tab 174 to counter-rotate, or rotate in an opposite direction,within the window 150. This counter rotation of the drive tab 174 causesthe drive tab to contact the second tooth 132 b and rotate the secondtooth 132 b and release sleeve 130 in the loosening direction, whichcauses the release sleeve 130 to rotate the coil spring's tang 136 andopen or widen the diameter of the coil spring 134 as described herein.Rotation of the drive tab 174 pushes the second tooth 132 b out of thewindow 150 and under the upper surface of the spool 140 until drive tab174 contacts a second edge 152 b of the window. The first tooth 132 a issimultaneously rotated within the window as illustrated. In this mannerthe knob 170 is rotatable in the loosening direction to engage therelease sleeve 130 and thereby reduce the frictional engagement of thecoil spring 134 about the lower hub 122, which allows the spool 140, theupper hub 126, and the coil spring 134 to rotate in the looseningdirection and thereby reduce the tension in the tension member byunwinding the tension member from the spool's annular channel 144. Thetension in the tension member, and/or the drive tab 174 pressing on thesecond edge 152 b, may cause the spool 140 to rotate in the looseningdirection.

Since the drive tab 174 is rotatable within the window 150 between thefirst edge 152 a and the second edge 152 g, the knob 170 will rotate bysome amount relative to the spool 140 before engaging with the spool 140and causing the spool 140 to rotate in the tightening or looseningdirection. In some embodiments the knob 170 may rotate between 3 and 20degrees relative to the spool 140 before engaging the spool, although arotation of between 5 and 10 degrees is more common. The relativerotation of the knob 170 about the spool 140 is important to ensure thatthe drive tab 174 contacts the second tooth 132 b before contacting thesecond edge 152 b. This allows the release sleeve 130 to rotate relativeto the spool 140 and to rotated relative to the upper and lower hubs,126 and 122, which opens the coil spring 134 and reduces the frictionalengagement of the coil spring 134 and lower hub 122 as previouslydescribed.

If the drive tab 174 simultaneously, or nearly simultaneously, contactsthe second tooth 132 b and the second edge 152 b, the coil spring 134may not open sufficiently and will remain frictionally engaged with thelower hub 122. This frictional engagement of the coil spring 134 andlower hub 122 may require the user to exert substantial force to loosenthe tension member and/or may provide a feeling that the system islocked, jammed, or otherwise faulty. Accordingly, maintaining a properorientation of the release sleeve's teeth, 132 a and 132 b, in relationto the window 150 and drive tabs 174 is highly desired in order toprovide a more consistent and comfortable user experience. The abovedescribed approach of fixing the coil spring 134 to the upper hub 126and directly inserting the tang 136 into the release sleeve 130 helpensure that the proper orientation of the upper hub 126, the coil spring134, the release sleeve 130, and the spool 140 is maintained, whichprovides a more uniform and consistent feel and operation of the reelsystem 100.

Referring briefly to FIGS. 26-30, illustrated is an alternativeembodiment of a friction based load holding mechanism that includes asingle hub 180 that frictionally engages with a coil spring 182. The hub180 and coil spring 182 are configured to be coaxially aligned andpositioned within the opening or channel 142 of the spool 140. The hub180 includes axially extending teeth 124 that fixedly secures the hub180 to the housing 102. The coil spring 182 includes a U-shaped tang 184that is configured to couple with a spool 140 by being positioned withina channel 141 of a bottom end of the spool 140 as illustrated in FIG.30. The U-shaped tang 184 eliminates the need for the upper end of thehub 180 to include axially extending teeth that engage with the spool140, which design may be employed in the upper hub 126 described herein.The tang 184 may also have a shape other than the U-shape illustrated inFIGS. 26-30. The spool 140 is fixedly secured to the housing 102 viaengagement of the axially extending teeth 124 of the hub 180 and thetang 184 of the hub 180.

FIG. 27 illustrates the coil spring 182 wound about an exterior surfaceof the single hub 180. As described herein, the coil spring 182 isdesigned to constrict about the hub 180 and thereby frictionally engagewith the hub 180 to prevent unwanted rotation of the spool 140 withinthe housing 102. The frictional engagement of the coil spring 182 andthe hub 180 provides the load holding property or function of thefriction based load holding mechanism. Specifically, the constriction ofthe coil spring 182 about the hub 180 locks or secures the spring 182about the hub 180, which locks or secures the spool 140 in positionrelative to the housing 102 since the spool 140 is secured to the hub180. Thus, unwanted rotation of the spool 140 within the housing 102 isprevented.

The knob 170, spool 140, and coil spring 182 are designed so that whenthe knob 170 is rotated in the tightening direction (e.g., Arrow A inFIG. 12), the spool 140 and coil spring 182 are able to rotate about thehub 180, which is fixed in positon about the housing 102. To ablerotation of the spool 140 and coil spring 182 about the hub 180, theknob 170 includes axially extending projections, 171 and 175, that arepositioned within corresponding recesses, 143 and 145, of the spool 140.The axially extending projections, 171 and 175, contact and engage withthe corresponding recesses, 143 and 145, of the spool 140 to transferrotational forces that are imposed on the knob 170 from the user. Therotational forces 140 cause the spool 140 to rotate about the hub 180.The coil spring 182 is able to rotate about the hub 180 due to thecoupling of the U-shaped tang 184 with the spool 140. Specifically, asthe spool 140 rotates in the tightening direction, the rotation of thespool 140 transfers a rotational force to the U-shaped tang 184, whichwidens a diameter of the coil spring 182 and reduces the frictionalengagement of the coil spring 184 and hub 180 to the point that rotationof the coil spring 182 about the hub 180 is enabled. Ceasing therotation of the knob 170 in the tightening direction causes the coilspring 182 to immediately reengage with the hub 180, which locks orsecures the spool 140 in position relative to the housing 102.

The knob 170, spool 140, and coil spring 182 are designed so that whenthe knob 170 is rotated in the loosening direction (e.g., Arrow B inFIG. 13), the spool 140 and coil spring 182 are also able to rotateabout the hub 180, which is fixed in positon about the housing 102. Theknob includes a release protrusion 179 that is configured to contact andengage with an upper tang 186 of the coil spring 182 when the knob 170is rotated in the loosening direction. Engagement of the releaseprotrusion 179 and upper tang 186 transfers a rotational force to theupper tang 186, which widens the diameter of the coil spring 182 andreduces the frictional engagement of the coil spring 182 and hub 180 tothe point that rotation of the coil spring 182 about the hub 180 isenabled. Since the frictional engagement of the coil spring 182 and hub180 is reduced, the tension in the tension member, and/or the rotationforces imposed on the knob 170, causes the spool 140 to rotate in theloosening direction. Ceasing the rotation of the knob 170 in theloosening direction causes the coil spring 182 to immediately reengagewith the hub 180, which locks or secures the spool 140 in positionrelative to the housing 102.

A method of assembly an article with a reel based tensioning device mayinclude providing a reel based tensioning device, in which the reelbased tensioning device includes a housing, a spool rotatably positionedwithin the housing, a knob member that is operably coupled with thespool to cause the spool to rotate within the housing, and a loadholding mechanism that includes a spring that frictionally engages witha cylindrical member to prevent unwanted rotation of the spool withinthe housing. The knob member may be operationally coupled with the loadholding mechanism so that a first operation of the knob member reducesthe frictional engagement of the spring and cylindrical member to allowrotation of the spool within the housing to wind a tension member aboutthe spool and so that a second operation of the knob member also reducesthe frictional engagement of the spring and cylindrical member to allowrotation of the spool within the housing to unwind the tension memberfrom about the spool. The method may also include coupling the reelbased tensioning device member with the article.

The spring may be a coil spring that is wound about an exterior of acylindrical hub member, in which the coil spring frictionally engageswith the hub member by constricting about an outer surface of the hubmember. In some embodiments, the hub member may include an upper hubmember that is fixedly secured to the spool and a lower hub member thatis fixedly secured to the housing. The upper hub member may have adiameter that is slightly larger than a diameter of the lower hub memberand a distal end of the upper hub member that interfaces with the lowerhub member may be tapered. Alternatively or additionally, the hub membermay be an inner hub member and the reel based tensioning device may alsoinclude an outer hub member that is disposed over the inner hub memberand that is operationally coupled with the knob member and the spring sothat rotation of the knob member in a loosening direction reduces thefrictional engagement of the spring and the inner hub member. The outerhub member may be coupled with the knob member so that rotation of theknob member in the loosening direction effects a rotation of the outerhub in the loosening direction. The spring may include a tang that iscoupled with the outer hub member so that rotation of the outer hubmember in the loosening direction effects a widening of a diameter ofthe spring, thereby reducing the frictional engagement of the spring andthe inner hub member. In other embodiments, the cylindrical member mayinclude a cylindrical channel or recess and the spring may be a coilspring that is biased radially outward into frictional engagement withan interior wall of the cylindrical channel or recess.

The friction based load holding mechanism 120 is typically a silentmechanism, which means that the friction based load holding mechanism120 produces essentially no audible sound or minimizes the amount ofaudible noise that is produced. The description ofnondetectable/undetectable audible noise as used herein refers to anynoise level below those outlined in MIL-STD-1474D, Req. 2, pgs. 20-32,the entire disclosure of which is incorporated by reference herein. Insome instances it may be desirable to provide audible feedback about theuse of the reel system 100. To provide the audible feedback, the reelsystem 100 may include a separate audible mechanism, such as a pawlsystem that produces an audible click when the reel system 100 isoperated. FIG. 14 illustrates an assembly of the components of thesystem that may be used to produce an audible click and FIG. 4illustrates a pawl member 160 of the audible mechanism. The pawl member160 includes an elongate body, a first end 162, and a second end 164.The first end 162 is configured to couple with the upper surface of thespool 140 while the second end 164 is configured to interact with teeth112 that are positioned on the interior region 116 of the housing 102.

As illustrated in FIG. 14, the first end 162 of the pawl member 160 ispositioned within a coupling slot or recess 156 of the spool 140. In theinstant embodiment, the first end 162 of the pawl member 160 is bent toform a loop that fits within the slot or recess 156 of the spool 140,although other methods of attaching the first end 162 of the pawl memberto the spool may be employed. When positioned within the housing 102,the pawl member 160 flexes and bends between the first end 162 and thesecond end 164. The elongate body of the pawl member 160 is positionedradially outward of a central portion 159 of the spool 140 and is flexedaround the central portion 159. In some embodiments, the pawl member 160may be positioned radially inward of an outer protrusion 157 of thespool 140. The outer protrusion 157 may hold the pawl member 160 inplace during assembly of the reel system 100 and/or affect theflexibility of the pawl member 160 in order to produce a desired audiblesound.

The second end 164 of the pawl member 160 contacts the inner surface andteeth 112 of the housing 102. The second end 164 may be shaped so thatthe second end 164 easily slides about the inner surface of the housing102 and is deflected into and out of the teeth 112. In one embodiment,the second end 164 of the pawl member has a U-shaped configuration,which allows the second end 164 to easily slide about the inner surfaceof the housing and minimizes engagement of the second end 164 of thepawl member 102 and the teeth 112 that would impeded or hinder suchmovement. Unlike conventional pawls, the second end 164 of the pawlmember 160 is not designed to restrict or appreciably resist rotation ofthe spool 140 within the housing 102.

As the spool 140 is rotated in either the tightening or looseningdirection within the housing 102, the second end 164 is deflected intoand out of adjacent teeth 112 of the housing 102. The second end 164produces an audible click noise as the second end 164 springs or bouncesinto engagement with each of the teeth 112 of the housing 102. As thespool 140 is rotated in one direction, the pawl member 160 is tensionedand the second end 164 is pulled into and out of each tooth 112 of thehousing 102. As the spool 140 is rotated in the opposite direction, thepawl member 160 is compressed and the second end 164 is pushed into andout of each tooth 112. In this manner, an audible click sensation isproduced as the reel system 100 is operated to both tension and loosenthe tension member.

The second end 164 of the pawl member 160 may be configured to producean essentially uniform sound regardless of the direction of rotation ofthe spool, or may be configured to produce a different sound for whenthe spool 140 is rotated in the tightening direction versus theloosening direction. For example, the second end 164 may be configuredto respond slightly differently when pulled into engagement with eachtooth 112 versus when it is pushed into engagement with each tooth,which may produce a different audible sound. The sound may also beadjusted by selecting the thickness of the pawl member 160, the lengthof the pawl member 160, and/or the number of teeth that are employed inthe system. In some embodiments, the spool 140 may include between about20 and 40 teeth, and more commonly between about 25 and 35 teeth. In aspecific embodiment, the spool 140 may include 32 teeth. The reel system100 could also implement multiple pawl members (e.g., two or more) witheach pawl member being employed during the tensioning or loosening ofthe tension member. In other embodiments, the audible mechanism couldinclude detents that engage to produce an audible sound or a linear pawlbeam that interacts with spline teeth.

A method of configuring a reel based tensioning device may includeproviding a reel based tensioning device, in which the reel basedtensioning device includes a housing, a spool that is rotatablypositioned within the housing, a knob member that is operably coupledwith the spool to cause the spool to rotate in a first direction withinthe housing to wind a tension member about the spool, and a load holdingmechanism that is coupled with the spool and that is configured to allowrotation of the spool in the first direction within the housing and toprevent rotation of the spool in a second direction within the housingto prevent unwinding of the tension member from about the spool.

The method may also include coupling an audible component with the reelbased tensioning device in which the audible component is configured toproduce an audible noise responsive to operation of the knob member tosignal an adjustment of the tension member. The method may also includeadjusting the audible component to adjust the audible noise that isproduced by the audible component.

The load holding mechanism may not produce an audible noise that isdetectable by a human ear. The audible component may be configured toproduce an audible noise responsive to tensioning of the tension memberand to produce an audible noise responsive to loosening of the tensionmember. The audible noise that is produced responsive to tensioning ofthe tension member may be different than the audible noise responsive toloosening of the tension member. The audible component may include apawl member or beam that engages with the housing to produce the audiblenoise. The pawl member or beam may be incapable of preventing rotationof the spool within the housing when an appreciable rotational force isimposed on the spool via the tension member or knob member. The loadholding mechanism of the reel base tensioning device may not include apawl member or beam.

In some instances, it may be beneficial to form a component of the reelsystem 100 directly onto a fabric material so that the fabric isintegrally formed with or integrated within the component. In someembodiments the fabric material may facilitate in attaching thecomponent with an article, such as attaching the component to a shoe. Ina specific embodiment, the component may be formed onto the fabricmaterial via insert molding in which the fabric material is positionedwithin a mold or die and a polymer material is injected atop or throughthe fabric material. The component of the reel system may be a firstcomponent that includes a top end, a bottom end, and an interior cavitywithin which a second component of the reel based tensioning system ispositionable. A specific example of a first component is a base memberor bayonet that is configured to couple with a housing of the reelsystem. Another example of a first component is a housing that isconfigured to couple with a spool and other components of the system asdescribed herein. Yet another example of a first component is a guidemember that includes an interior cavity that is configured to receive atension member of the reel system in order to guide the tension memberabout a path of an article.

When the component is formed onto the fabric material, the fabricmaterial may be positioned near the bottom end of the component and mayextend laterally from at least a portion of an outer periphery of thecomponent, and more commonly around the entire periphery of thecomponent. The fabric material may be integrally coupled with the firstcomponent by injecting the polymer material (i.e., thermoplastic orthermoset material) of the component through the fabric material so thatthe polymer material of at least a portion of the component is saturatedor impregnated through the fabric material with the polymer materialextending axially bellow a bottom surface of the fabric material andaxially above a top surface of the fabric material. In some embodimentsthe polymer material may be saturated or impregnated through the fabricmaterial so that an entire bottom end of the component extends axiallybellow the bottom surface of the fabric material and axially above thetop surface of the fabric material. In such embodiments, the polymermaterial of the component's bottom end may form an annular ring on thebottom surface of the fabric material. In other embodiments only aportion of the bottom end may extend axially above and below the fabricmaterial with the remaining portion of the bottom end positioned only onone side of the fabric material.

Referring now to FIGS. 15, 17-19, and 23-25 illustrated is the basemember 220 attached to a piece of woven material, such as fabric 200.The fabric may be essentially any fabric, such as a polymer basedfabric. In a specific embodiment, the fabric may be a 500 denierpolyester fabric. FIG. 17 illustrates the base member 220 unattachedfrom the fabric 200 while FIG. 18 illustrates a perspective view of thebase member 220 attached to the fabric 200. As illustrated in FIG. 18,the fabric 200 is substantially flush with a bottom surface of the basemember 220 after the base member 220 is attached to the fabric 200. Thefabric 200 extends laterally from at least a portion of an outerperiphery of the base member 220 and more commonly around an entireperiphery of the base member 220. FIG. 15 and FIG. 24 illustrate bottomviews of the fabric 200 and base member 220 showing alternativeattachment configurations of the base member 220 and fabric 200. FIG. 23illustrates a bottom view of an embodiment of the fabric 200 prior toforming the base member 220 onto the fabric 200. FIG. 19 illustrates across sectional view of an embodiment of an attached base member 220 andfabric 200.

In an exemplary embodiment, the base member 220 is directly injectedonto the fabric 200. This is achieved by insert molding or injecting thematerial of the base member 220 through a bottom surface of the fabric200, which results in a significantly high adhesion strength andprevents or minimizes separation of the base member 220 from the fabric200. For example, direct injection of the base member's material throughthe bottom surface of the fabric 200 may enable the materials toexperience a 50 Kg force before beginning to separate. The material ofthe base member 220 is commonly a polymer material (i.e., thermoplasticor thermoset material), which is injected through the fabric 200 so thatwhen the base member 220 is formed, the fabric 200 is disposed within atleast a portion of the base member 220 so that the polymer material isdisposed on opposite sides of the fabric 200. The positioning of thefabric 200 within the base member 220 is shown in FIGS. 15, 19, and 24.

As illustrated in FIG. 17, the base member 220 may be a component of thesystem that includes an interior cavity that is configured to receiveand releasably couple with a housing 102 as shown in FIG. 16. In otherembodiments, the base member may be a housing component, such as the oneillustrated in FIG. 16, which may be directly injected onto, andintegrally formed with, the fabric 200. In such embodiments, the needfor a separate base member 220 and housing 102 may be eliminated andthese components may be integrated into a single component that isintegrally coupled with the fabric 200. The housing component mayinclude lace ports 104 through which a tension member or lace isdisposed.

In some instances, the material of the base member may be injected intothe fabric 200 so that the saturation or integration of the materialwithin the fabric 200 is varied. The term saturation or integration ofthe base member's material within the fabric 200 refers to the amount ofthe base member's material that remains disposed within the interior ofthe fabric 200 after the injection process. When the base member'smaterial is highly saturated/integrated within the fabric 200, theinjected base member material is essentially positioned on both sides ofthe fabric 200 and through the interior of the fabric. When the basemember's material is less saturated/integrated within the fabric 200,the injected base member material does not fully penetrate through thefabric 200 or is essentially positioned on one side of the fabric 200.The fabric is more readily visible in areas where the base member'smaterial is less saturated/integrated within the fabric 200. In aspecific embodiment, the base member's material is glass filledpolypropylene and/or co-polyester.

In one embodiment, the saturation/integration of the base member'smaterial may vary from between segments or portions of the base memberso that the base member's material is highly saturated/integratedthrough the fabric 200 in one segment or portion of the base member andless saturated/integrated through the fabric 200 in another segment orportion of the base member. In such an embodiment, the variance of thebase member's material within the fabric 200 is illustrated by the crosshatching or shaded areas of FIGS. 15 and 19. The cross hatching orshaded areas represent portions of the fabric 200 where the basemember's material is more saturated or integrated into the fabric 200.These areas may appear darker or of a slightly different color due tothe base member's material being more concentrated in these areas andmore visible from a bottom surface of the fabric 200. The variance ofthe saturation/integration of the base member's material may be designedto provide a desired property, such as increased bond or adhesionstrength between the two materials, increased strength of the basemember, etc.

The strength of the bond or adhesion between the fabric 200 and basemember 220 may be substantially increased when the base member'smaterial is highly saturated/integrated within the fabric 200. However,the strength of the base member 220 itself may be decreased when thebase member's material is highly saturated/integrated within the fabric200 due to less material being present within the base member. Thedecreased strength of the base member 220 may negatively affect how thebase member 220 interacts with other components of the system, such asthe housing 102. For example, a wall 224 that is opposite the front tab222 may be a thinner section of material in order to reduce the sizeand/or weight of the base member 220. If the base member 220 is too thinnear the wall 224, the wall 224 may crack or break from the pressure orforce that is exerted on the wall 224 by the housing 102. As such, itmay be desirable to construct the base member 220 and fabric 200 so thatthe wall 224 remains relatively strong and reinforced while an increasedbond/adhesion between these materials is achieved due to saturation ofthe base member's material within the fabric 200.

In some instances, the base member 220 may experience greater externalforces near the front tab 222. The external force may urge or cause thebase member 220 to peel away from the fabric 200 and thus, an increasedbond/adhesion strength near the front tab 222 may be desired. The wall224 may be used primarily to couple the base member 220 with the housing102 and thus, it may be more desirable to reinforce or strength the basemember 220 adjacent the wall 224. This increased bond/adhesion strengthnear the front tab 222 and the increased reinforcement of the basemember 220 near the wall 224 may be achieved by increasing thesaturation/integration of the base member's material near the front tab222 while decreasing the saturation/integration of the base member'smaterial near the wall 224 as shown in FIGS. 15 and 19.

In one embodiment, the amount of saturation/integration of the basemember's material within the fabric 200 may be controlled based on thearrangement of injection holes 226 that inject the base member'smaterial through the fabric 200. The base member's material may morefully saturate/integrate into the fabric 200 around the injection holes226 and thus, the injection holes 226 may be positioned adjacent areasof the base member 220 where an increased bond/adhesion strength isdesired and may not be positioned in areas where increased componentstrength is desired. FIGS. 15 and 19 illustrate the injection holes 226positioned near the front tab 222 where the cross-hatching or shading isillustrated and where increased saturation/integration of base member'smaterial and fabric 200 is typically desired. In this manner, the holepattern may be engineered to provide a designed combination of desiredstrength without compromising the integrity of the component.

In another embodiment, the saturation/integration of the base member'smaterial may be relatively uniform relative to the base member so thatthe base member's material is either highly saturated/integrated throughthe fabric 200 or slightly saturated/integrated through the fabric 200.FIG. 24 illustrates a bottom view of the fabric 200 that shows a uniformsaturate/integration of the polymer material through the fabric. In FIG.24, the base member's material is highly saturated/integrated throughthe fabric 200, which results in the fabric 200 being disposed withinthe polymer material of essentially an entire bottom end of the basemember 220. The description of the fabric 200 being disposed within thepolymer material of the base member 220 means that the polymer materialis disposed or positioned on opposite sides of the fabric 200. Since thebase member 220 has an essentially cylindrical configuration as shown inFIG. 17 (i.e., a circular bottom end and hollow interior), thepositioning of the polymer material on opposite sides of the fabric 200results in the formation of an annular ring 223 on a bottom surface ofthe fabric 200 as illustrated in FIG. 24. When the bottom end of thebase member 220 has a different configuration (e.g., planar surface,oval shave, etc.), the shape that is formed on the bottom surface of thefabric 200 would correspond to the shape of the bottom end of the basemember 220.

As shown in FIG. 25, in some embodiments the base member 220 includesone or more thinner material sections 225. Since the fabric 200 isdisposed or positioned within the base member's material, the fabric 200may be visible on a top surface of the thinner material sections 225 ofthe base member 220. FIG. 23 illustrates a view of the fabric 200 beforethe base member's material has been injected through the fabric 200. Thefabric 200 includes injection holes 226 that are arranged to facilitatein saturation/integration of the polymer material through the fabric 200to form the annular ring 223 illustrated in FIG. 24. FIG. 23 alsoillustrates the fabric 200 includes a plurality of tabs 240 that extendlaterally outward from a main body of the fabric 200. One or more of thetabs 240 may include an aperture 241 as illustrated.

While the variance of the material saturation/integration within thefabric 200 is shown in relation to the base member 220, it should berealized that other components of the system may likewise be directlyinjected onto a fabric, such as a guide member for the tension memberand other components. Thus, the general description above is related toany reel system component and not specifically to base members.

A method of forming a component of a reel based tensioning system mayinclude providing a fabric material and positioning the fabric materialwithin a die or mold. The method may also include injecting a polymermaterial through the fabric material so that the polymer material fillsa void or space within the die or mold that defines a shape of a firstcomponent of the reel based tensioning system. The method may alsoinclude cooling the polymer material so that the polymer materialhardens and forms the first component of the reel based tensioningsystem. The polymer material of at least a portion of the firstcomponent is saturate or impregnate through the fabric material so thatthe polymer material of the first component extends axially bellow abottom surface of the fabric material and axially above a top surface ofthe fabric material. The fabric material may be positioned within abottom end of the die or mold so that the polymer material is injectedthrough the fabric material from the bottom end of the die or moldtoward a top end of the die or mold. The bottom end of the die or moldmay correspond to a bottom end of the first component. The polymermaterial may be injected through the fabric material and cooled so thatthe polymer material of an entire bottom end of the first component issaturated or impregnated through the fabric material. In such instances,the polymer material of the entire bottom may extend axially bellow thebottom surface of the fabric material and axially above the top surfaceof the fabric material. The polymer material may be injected through thefabric material and cooled so that the polymer material forms an annularring atop the bottom surface of the fabric material. The polymermaterial may comprise or consists of a glass filled polypropylenematerial, a co-polyester material, or a combination thereof. The polymermaterial may be injected through the fabric material and cooled so thatthe polymer material is visible from a top surface of a materiallythinner section or segment of the first component.

Referring now to FIG. 20, illustrated is a stop cord or mechanism 230that is attached to the spool 140 and the housing 102. The stop cord 230is wound around a stop cord channel 232 that is separate from theannular channel 144. The stop cord 230 is wrapped around the stop cordchannel 232 so that as the tension member is unwound from the annularchannel 144, the stop cord 230 wraps around the stop cord channel 232.The length and arrangement of the stop cord 230 and the stop cordchannel 232 is such that when the tension member is fully or mostlyunwound from the annular channel 144, the stop cord 230 is mostly orfully wrapped around the stop cord channel 232, which prevents furtherrotation of the spool 140 within the interior region 116 of the housing102. In this manner, the stop cord 230 prevents back-winding of thetension member about the annular channel 144—i.e., winding of thetension member around the annular channel 144 when the spool is rotatedin the loosening direction. The function and arrangement of the stopcord is further described in U.S. Pat. No. 9,259,056, filed Jun. 21,2013, and entitled “Reel Based Lacing System,” the entire disclosure ofwhich is incorporated by reference herein.

To attach the stop cord 230 to the reel system 100, a proximal end ofthe stop cord 230 is inserted through a coupling aperture 108 in thehousing and a knot is tied in the proximal end of the stop cord 230. Theknot engages with the coupling aperture 108 to prevent the proximal endof the stop cord 230 from being pulled through the coupling aperture108. A distal end of the stop cord 230 is similarly inserted through apair of apertures (not shown) in the spool 140 and a knot is tied in thedistal end of the stop cord 230. The knot engages with an uppermostaperture (not shown) to prevent the distal end of the stop cord 230 frombeing pulled through the spool 140. When the knot in the distal end ofthe stop cord 230 is engaged with the spool's aperture, the knot ispositioned within a slot 109 of the spool 140. In some instances, asmall portion of the stop cord 230 extends across the spool's annularchannel 144. In such instances, the tension member (not shown) is woundaround the stop cord 230.

FIGS. 21-22 illustrate an alternative embodiment of a coil spring 400and release hub assembly. Specifically, the coil spring 400 isconfigured to be positioned within an upper hub 326 and a lower hub 322.An outer diameter of the coil spring 400 is approximately the same sizeas or slightly larger than an inner diameter of the upper hub 326 andlower hub 322 so that the spring 400 flexes outward into frictionalengagement with the upper hub 326 and the lower hub 322 in order to lockthe two hubs together in a manner similar to that described herein. Asshown in FIG. 22, the lower hub 322 is fixedly secured to the housing ofthe reel system 500 via axially extending teeth 324 while the upper hub326 is fixed to the spool of the reel system 500 via axially extendingteeth 328. Locking the upper hub 326 and the lower hub 322 togetherprevents the upper hub 326 from rotating relative to the lower hub 322,which locks the spool in position relative to the housing.

To unlock the upper hub 326 from the lower hub 322, the diameter of thecoil spring 400 is reduced. The coil spring 400 includes a tang 402 thatextends radially inward and that engages a release sleeve (not shown) ora component of the knob. As the knob is rotated in a looseningdirection, the tang 402 is engaged, via the release sleeve or acomponent of the knob, which causes the spring coil 400 to be wound in adirection that causes the coil spring to constrict or move radiallyinward thereby (i.e., a counter-clockwise direction for the spring shownin FIG. 21). Movement of the coil spring 400 in this manner causes thecoil spring's outer diameter to decrease to the point where the upperhub 326 is unlocked from the lower hub 322 and is able to rotatedrelative to the lower hub 322, which allows the spool to rotate withinthe housing in the loosening direction.

The upper hub 326 and lower hub 322 may have different sized innerdiameters, may be made of different materials, and/or may have differentsurface finishes to ensure that the coil spring 400 is rotatable aboutone of the hubs while remaining fixed to the other hub as desired. Whena release sleeve is employed, the release sleeve may be a cylindricalsleeve that fits entirely within the interior of the coil spring 400 ina manner that minimizes frictional engagement of the release sleeve andcoil spring 400. In addition, although the tang 402 is shown positionednear the outer end of the upper hub 326, in other embodiments the tang402 may be positioned adjacent an outer end of the lower hub 322.

While several embodiments and arrangements of various components aredescribed herein, it should be understood that the various componentsand/or combination of components described in the various embodimentsmay be modified, rearranged, changed, adjusted, and the like. Forexample, the arrangement of components in any of the describedembodiments may be adjusted or rearranged and/or the various describedcomponents may be employed in any of the embodiments in which they arenot currently described or employed. As such, it should be realized thatthe various embodiments are not limited to the specific arrangementand/or component structures described herein.

In addition, it is to be understood that any workable combination of thefeatures and elements disclosed herein is also considered to bedisclosed. Additionally, any time a feature is not discussed with regardin an embodiment in this disclosure, a person of skill in the art ishereby put on notice that some embodiments of the invention mayimplicitly and specifically exclude such features, thereby providingsupport for negative claim limitations.

Having described several embodiments, it will be recognized by those ofskill in the art that various modifications, alternative constructions,and equivalents may be used without departing from the spirit of theinvention. Additionally, a number of well-known processes and elementshave not been described in order to avoid unnecessarily obscuring thepresent invention. Accordingly, the above description should not betaken as limiting the scope of the invention.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassed.The upper and lower limits of these smaller ranges may independently beincluded or excluded in the range, and each range where either, neitheror both limits are included in the smaller ranges is also encompassedwithin the invention, subject to any specifically excluded limit in thestated range. Where the stated range includes one or both of the limits,ranges excluding either or both of those included limits are alsoincluded.

As used herein and in the appended claims, the singular forms “a”, “an”,and “the” include plural referents unless the context clearly dictatesotherwise. Thus, for example, reference to “a process” includes aplurality of such processes and reference to “the device” includesreference to one or more devices and equivalents thereof known to thoseskilled in the art, and so forth.

Also, the words “comprise,” “comprising,” “include,” “including,” and“includes” when used in this specification and in the following claimsare intended to specify the presence of stated features, integers,components, or steps, but they do not preclude the presence or additionof one or more other features, integers, components, steps, acts, orgroups.

1. An insert molded component for a reel based tensioning device, thereel based tensioning device being coupled with a tension member andbeing operable to tension the tension member, the insert moldedcomponent comprising: a base member of the reel based tensioning device,the base member being made of a polymer material, the base member havinga top end and a bottom end with a bottom surface and having an interiorcavity within which one or more components of the reel based tensioningdevice are positionable; and a fabric material that is substantiallyflush with the bottom surface of the base member and that extendslaterally from at least a portion of an outer periphery of the bottomend of the base member, the base member being insert molded onto thefabric material by injecting the polymer material through the fabricmaterial so that when the insert molded component is formed, the fabricmaterial is disposed within at least a portion of the base member withthe polymer material of the least a portion of the base member disposedon opposite sides of the fabric material.
 2. The insert molded componentaccording to claim 1, wherein the interior cavity of the base member isconfigured for receiving a housing component of the reel basedtensioning device.
 3. The insert molded component according to claim 1,wherein the base member is a housing component of the reel basedtensioning device, the housing component including entry and exits portsthrough which the tension member is disposed such that the tensionmember passes from an interior portion of the housing component to anexterior portion of the housing component.
 4. The insert moldedcomponent according to claim 1, wherein the base member is insert moldedonto the fabric material so that the fabric material is disposed withinthe entire bottom end of the base member such that the polymer materialof the entire bottom end of the base member is disposed on oppositesides of the fabric material.
 5. The insert molded component accordingto claim 4, wherein the polymer material of the bottom end of the basemember forms an annular ring on a bottom surface of the fabric material.6. The insert molded component according to claim 1, wherein the basemember includes at least one thinner polymer material section andwherein the fabric material is visible on a top surface of the thinnerpolymer material section of the base member.
 7. The insert moldedcomponent according to claim 1, wherein the base member is made of aglass filled polypropylene material, a co-polyester material, or acombination thereof.
 8. The insert molded component according to claim1, wherein the fabric material is attachable to a shoe.
 9. A componentof a reel based tensioning system comprising: a first component of thereel based tensioning system, the first component being made of apolymer material and having a top end, a bottom end, and an interiorcavity within which a second component of the reel based tensioningsystem is positionable; and a fabric material that is positioned nearthe bottom end of the first component and that extends laterally from atleast a portion of an outer periphery of the first component, the fabricmaterial being integrally coupled with the first component by injectingthe polymer material of the first component through the fabric materialso that the polymer material of at least a portion of the firstcomponent is saturated or impregnated through the fabric material and sothat the polymer material of the at least a portion of the firstcomponent extends axially bellow a bottom surface of the fabric materialand axially above a top surface of the fabric material.
 10. Thecomponent according to claim 9, wherein the first component is a basemember and wherein the interior cavity of the base member is configuredfor receiving a housing component of a reel based tensioning device. 11.The component according to claim 9, wherein the first component is aguide member and wherein the interior cavity is configured to receive atension member of the reel based tensioning system in order to guide thetension member about a path of an article.
 12. The component accordingto claim 9, wherein the polymer material of the entire bottom end of thefirst component is saturated or impregnated through the fabric materialso that the polymer material of the entire bottom end extends axiallybellow the bottom surface of the fabric material and axially above thetop surface of the fabric material.
 13. The component according to claim12, wherein the polymer material of the bottom end of the firstcomponent forms an annular ring on the bottom surface of the fabricmaterial.
 14. The component according to claim 9, wherein the fabricmaterial comprises a plurality of tabs that extend laterally outwardfrom a main body of the fabric material and wherein at least one of thetabs includes an aperture.
 15. The component according to claim 9,wherein the fabric material is visible from a top surface of amaterially thinner section or segment of the first component.
 16. Amethod of forming a component of a reel based tensioning system, themethod comprising: providing a fabric material; positioning the fabricmaterial within a die or mold; injecting polymer material through thefabric material so that the polymer material fills a void or spacewithin the die or mold that defines a shape of a first component of thereel based tensioning system; and cooling the polymer material so thatthe polymer material hardens and forms the first component of the reelbased tensioning system; wherein the polymer material of at least aportion of the first component is saturated or impregnated through thefabric material so that the polymer material of the at least a portionof the first component extends axially bellow a bottom surface of thefabric material and axially above a top surface of the fabric material.17. The method of claim 16, wherein the fabric material is positionedwithin a bottom end of the die or mold, and wherein the polymer materialis injected through the fabric material from the bottom end of the dieor mold toward a top end of the die or mold.
 18. The method of claim 16,wherein the polymer material is injected through the fabric material andcooled so that the polymer material of an entire bottom end of the firstcomponent is saturated or impregnated through the fabric material suchthat the polymer material of the entire bottom end extends axiallybellow the bottom surface of the fabric material and axially above thetop surface of the fabric material.
 19. The method of claim 18, whereinthe polymer material is injected through the fabric material and cooledso that the polymer material forms an annular ring atop the bottomsurface of the fabric material.
 20. The method of claim 16, wherein thepolymer material consists of a glass filled polypropylene material, aco-polyester material, or a combination thereof
 21. The method of claim16, wherein the polymer material is injected through the fabric materialand cooled so that the polymer material is visible from a top surface ofa materially thinner section or segment of the first component. 22.-70.(canceled)